Thermoforming: the route, the tolerances it holds, materials and design tips, with an indicative cost. One of 56 processes in the free finder.
PolymerFamily
+/-0.3mmTypical tol.
5Route steps
70Parts in finder
Thermoforming heats a plastic sheet until pliable and draws it over a mould with vacuum or pressure, trimming the formed part from the sheet.
At a glance
When to use it, and when not
Best for
Trays, blisters, panels, clamshells and aligners at low to medium tooling cost.
Watch for
Open shapes with wall thinning in deep draws; trimming adds a step.
Step by step
The typical route
Raw material to finished part. Steps vary with material, volume and tolerance; this is the free route from the finder.
Heat sheet
Heat the plastic sheet to forming temperature.
Tooling - Tolerance - Lead -
Form
Vacuum/pressure-form over the mold.
Tooling Mold Tolerance - Lead -
Trim
Trim the part from the web (CNC/die).
Tooling - Tolerance - Lead -
Assemble
Bond/assemble if multi-part.
Tooling - Tolerance - Lead -
Inspect
Check draw and trim dimensions.
Tooling - Tolerance - Lead -
Precision
Tolerances it can hold
TYPICAL TOLERANCE IT CAN HOLD
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials it suits
Grade
Why it suits this
ABS/HIPS sheet
Easy to form
PETG
Clear, tough
Polycarbonate
Impact, clarity
Design
Design tips
A few general pointers for Thermoforming. The full, part-specific DFM list is in the dossier.
Deep draw with sharp corners.Add draft + radii.
Tight tolerance expected.Design loose; it's a forming process.
Cost
What it costs
Trays, panels, packaging from heated sheet; low tooling, great for large light parts at low-to-mid volume.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for your part at your volume, in your currency, are in the dossier.
MODEL EST.
$29 to 82per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on this process and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
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Thermoforming heats a plastic sheet until pliable and draws it over a mould with vacuum or pressure, trimming the formed part from the sheet. The typical route is: Heat sheet; Form; Trim; Assemble; Inspect. Trays, blisters, panels, clamshells and aligners at low to medium tooling cost.
What does Thermoforming cost per part?
It depends on size, tolerance and volume. As a rough ballpark it starts around $29 to 82 per part at low volume and falls with quantity. The dossier gives should-cost at your exact volume and currency. Model estimates, not quotes.
What tolerance can Thermoforming hold?
Typically about +/-0.3 mm, tighter with extra finishing operations at higher cost.
What materials suit Thermoforming?
Common choices are ABS/HIPS sheet (Easy to form); PETG (Clear, tough); Polycarbonate (Impact, clarity).
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
